FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the
TDM900 (S) 2004. For complete service information procedures it is necessary to use this Supplemen-
tary Service Manual together with the following manual.

TDM900 (N) 2001 SERVICE MANUAL: 5PS1-AE1

TDM900 (R) SUPPLEMENTARY SERVICE MANUAL: 5PS1-AE2

TDM900 (S) 2004

SUPPLEMENTARY
SERVICE MANUAL
E2003 by Yamaha Motor Co., Ltd.
First Edition, September 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.

NOTE:
Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

WARNING
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter.
Refer to “SYMBOLS”.
2 Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) ap-
pears.
3 Sub-section titles appear in smaller print than the section title.
4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6 Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequen-
tially. 2 1

3
4

8
5

7
 EAS00008

1 2
SYMBOLS
GEN The following symbols are not relevant to every
SPEC vehicle.
INFO Symbols 1 to 9 indicate the subject of each
3 4 chapter.
1 General information
CHK 2 Specifications
ADJ CHAS 3 Periodic checks and adjustments
4 Chassis
5 6 5 Engine
6 Cooling system
ENG COOL 7 Fuel injection system
8 Electrical system
9 Troubleshooting
7 8

FI ELEC Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted
11 Filling fluid
9 10
12 Lubricant
TRBL 13 Special tool
14 Tightening torque
SHTG 15 Wear limit, clearance
11 12 16 Engine speed
17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-

13 14
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
20 Molybdenum-disulfide oil
15 16 17 21 Wheel-bearing grease
22 Lithium-soap- based grease
23 Molybdenum-disulfide grease

18 19 20 Symbols 24 to 25 in the exploded diagrams indi-

cate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part

21 22 23

24 25
 CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHASSIS
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 16
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ELECTRICAL
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
KEY ID REGISTRATION METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SELF-DIAGNOSIS ERROR CODE INDICATION . . . . . . . . . . . . . . . . 25
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CHECKING THE IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . . . . 27
REPLACEMENT PARTS ON TROUBLES . . . . . . . . . . . . . . . . . . . . . . 29

TDM900 (S) 2004 WIRING DIAGRAM

 GENERAL SPECIFICATIONS/CHASSIS SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5PS6 (for EUR) SSS
5PS7 (for OCE) SSS

CHASSIS SPECIFICATIONS
Item Standard Limit
Front suspension
Suspension type Telescopic fork SSS
Front fork type Coil spring/oil damper SSS
Front fork travel 150 mm (5.91 in) SSS
Spring
Free length 349.9 mm (13.78 in) 342.9 mm
(13.50 in)
Spacer length 125 mm (4.92 in) SSS
Installed length 332.9 mm (13.11 in) SSS
Spring rate (K1) 5.39 N/mm (0.55 kg/mm, 30.78 lb/in) SSS
Spring rate (K2) 7.84 N/mm (0.80 kg/mm, 44.77 lb/in) SSS
Spring stroke (K1) 0 X 82 mm (0.00 X 3.23 in) SSS
Spring stroke (K2) 82 X 150 mm (3.23 X 5.91 in) SSS
Optional spring available No SSS
Fork oil
Recommended oil Yamaha fork oil 10 W or equivalent SSS
Quantity (each front fork leg) 545 cm3 (19.22 lmp oz, 18.43 US oz) SSS
Level (from the top of the inner 127 mm (5.00 in) SSS
tube, with the inner tube fully
compressed, and without
the fork spring)
Inner tube outer diameter 43 mm (1.69 in) SSS
Inner tube bend SSS 0.2 mm (0.008 in)
Spring preload adjusting positions
Minimum 8 SSS
Standard 7 SSS
Maximum 1 SSS
Rebound damping adjusting
positions
Minimum 1 SSS
Standard 2 SSS
Maximum 4 SSS

–1–
 CHASSIS SPECIFICATIONS/
ELECTRICAL SPECIFICATIONS SPEC

Item Standard Limit

Front brakes
Brake type Dual-disc brake SSS
Operation Right-hand operation SSS
Recommended fluid DOT 4 SSS
Brake discs
Diameter thickness 298 5 mm (11.73 0.20 in) SSS
Min. thickness SSS 4.5 mm (0.18 in)
Max. deflection SSS 0.1 mm (0.0039 in)
Brake pad lining thickness 4.5 mm (0.18 in) 0.5 mm (0.02 in)
Master cylinder inside diameter 16 mm (0.63 in) SSS
Caliper cylinder inside diameter 30.2 mm and 27 mm (1.19 1.06 in) SSS
Drive chain:
Type (manufacturer) DID525HV KAI (DAIDO) SSS
Link quantity 118 SSS
Drive chain slack 50 X 60 mm (1.97 X 2.36 in) SSS
Maximum ten-link section SSS 159.5 mm (6.28 in)

ELECTRICAL SPECIFICATIONS
Item Standard Limit
Horn
Horn type Plane SSS
Model (manufacturer) quantity HF-12 (NIKKO) 1 SSS
Max. amperage 3A SSS
Performance 105 X 118 db/2 m (6.56 in) SSS
Coil resistance 1.01 X 1.11 Ω SSS
Indicator light
(voltage /wattage quantity)
Neutral indicator light 14 V 1.2 W 1 SSS
Turn signal indicator light 14 V 1.2 W 2 SSS
Oil level warning light LED 1 SSS
High beam indicator light 14 V 1.4 W 1 SSS
Engine trouble warning light 14 V 1.4 W 1 SSS
Immobilizer system indicator light LED 1 SSS
Fuses (amperage quantity)
Main fuse 40 A 1 SSS
Fuel injection system fuse 15 A 1 SSS
Headlight fuse 15 A 1 SSS
Signaling system fuse 10 A 1 SSS
Ignition fuse 10 A 1 SSS
Radiator fan motor fuse 20 A 1 SSS
Hazard light fuse 10 A 1 SSS
Parking light fuse 5A 1 SSS
Backup fuse 5A 1 SSS
Reserve fuse 20 A 1 SSS
15 A 1 SSS
10 A 1 SSS
5A 1 SSS

–2–
 CABLE ROUTING SPEC

CABLE ROUTING
1 Throttle cables 13 Turn signal light (right)
2 Clutch cable 14 Headlight sub-wire harness
3 Handlebar switch lead (left) 15 Auxiliary light lead
4 Main switch lead and immobilizer lead 16 Stay 3
5 Cover 7 17 Turn signal light (left)
6 Horn lead 18 Meter lead
7 Horn 19 Auxiliary light
8 Cover 8 20 Meter
9 Brake hose 21 Stay 1
10 Handleber switch lead (right) 22 Headight coupler
11 Front fork 23 Headilight adjusting knob
12 Clamp

–3–

A Fasten the handlebar switch lead (left) to the han-
dlebar with a band.
B Through the handlebar switch lead (left) and clutch
cable to the wire guide on the upper bracket.
C Fasten the main switch lead and immobilizer lead to
the wire guide with a clamp. There should be no
slack between main switch and wire guide. Cut the
clamp tip leaving 3 to 8 mm (0.12 to 0.31 in).
D Route the main switch lead through the cover 7 so
that it route beneath the handlebar switch lead (left).
E Route the clutch cable through the hole in front of
the head pipe on the frame.
F Route the handlebar switch lead (right) and throttle
cables (2 cables) through the cover 8.
–4–
CABLE ROUTING SPEC
G Route the brake hose through the guide.
H Always route the hose so that the brake hose
passes by the outside of the throttle cables.
I Route the handlebar switch lead (right), brake hose
and throttle cables through the wire guide of the up-
per bracket.
J Fasten the handlebar switch lead (right) to the han-
dlebar with a band.
K Fasten the main switch lead and immobilizer lead
with a clamp so that it faces the front side of the ve-
hicle.
L Fasten the horn lead to the front (left side) with a
clamp as shown in the drawing. Cut the clamp tip
leaving 3 to 8 mm (0.12 to 0.31 in).

M Fasten the horn lead to the upper side of the under
bracket as shown in the drawing. Cut the clamp tip
leaving 3 to 8 mm (0.12 to 0.31 in).
N 10 mm (0.39 in)
O Fasten the turn signal light lead (right) together with
the coupler to the stay 1.
P Clamp the white tape of headlight sub-wire harness
to the stay 1. (For detail of the clamp, refer to section
BB.)
Q Fasten the main harness and turn signal light lead
(left) together with the coupler to the stay 1.
And locate the turn signal light lead, under the wire
harness.
R Route the main harness through the outside of the
bolt.
S To the headlight relay.
–5–
CABLE ROUTING SPEC
T To the ECU.
U After the clamping, direct the band point to the front.
V Clamp the meter lead, indicator lead, headlight lead
and sub-wire harness to the stay 1 with a band.
W Route the all leads through inside of the headlight
adjusting knob. Because of the protruding of the
wire harness, it does not have to become the distur-
bance of operation of the headlight adjusting knob.
X Clamp the headlight sub-wire harness to the dent in
the stay 1.
Y Clamp the headlight sub-wire harness to the stay 1
with a band.
Z Fasten the headlight sub-wire harness with the
clamp that is passed through the center hole of stay
1.
 CABLE ROUTING SPEC
1 Stay 3 12 Seat lock cable 23 Headlight relay
2 Ignition coil assembly 13 Immobilizer coupler 24 ECU
3 Neutral switch lead 14 Tail/ brake light lead 25 ECU lead
4 O2 sensor lead 15 Rear turn signal light (left) 26 Stay 1
5 Speed sensor lead 16 Rear turn signal light lead (left) 27 4 poles waterproof coupler
6 Sidestand switch lead 17 Rectifier/ regulator lead 28 Plate
7 Pickup coil lead 18 Rear shock absorber 29 Boss
8 Air filter drain hose 19 Swingarm 30 Starter relay lead
9 Coolant reservoir tank drain hose 20 Sidestand switch 31 Oil pipe
10 Fuel tank drain hose 21 O2 sensor 32 Engine
11 Battery negative lead 22 Cylinder identification sensor 33 Frame
lead

–6–

A To the headlight.
B Route the 4 poles water proof coupler through in-
side of the ECU lead, and the 10 poles coupler
through outside of the ECU lead.
C Connect the headlight sub-wire harness coupler in
front of ECU and make it not to route above the ECU
lead.
D Fasten the wire harness to the stay 1 with a clamp.
The clump through the hole of the stay 1. The knot
should be faced to the outside of the vehicle.
E Pass the cylinder identification sensor lead above
the left radiator hose.
F Pass the rectifier / regulator lead above the frame
cross tube.
G Route the tail / brake light lead through the guides (3
places) of the tail / brake lgiht bracket.
–7–
CABLE ROUTING SPEC
H Fasten the tail / brake light lead at outside of the
frame with a clamp. After connecting the tail / brake
light lead coupler, insert the surplus wiring between
frame, and positioning without routing above the
frame.
I Fasten the rectifier / regulator lead with the clamp
installed with the rear fender. The clamp tip should
face the inner side of the vehicle.
J Route the fuel drain hoses (2 hoses), air filter case
drain hose, and coolant reservoir tank drain hose
trough the clamp. For the fuel drain hose, the white
paint mark should be under the clamp. The position
is regardless of ranks. Arrange the end of coolant
reservoir tank drain hose, air filter case drain hose
and fuel drain hose from the clamp.

K The O2 sensor lead should not stick out from the
boss seat face to the outside of the vehicle.
L Fasten the neutral switch lead, O2 sensor lead,
speed sensor lead, sidestand switch lead and recti-
fier / regulator lead with the clamp as shown in the
drawing. Cut the clamp tip leaving 3 to 8 mm (0.12 to
0.31 in) and make if face to the outside of the ve-
hicle.
M Less than 20 mm (0.79 in)
N Fasten the cylinder identification sensor lead to the
inner side of the frame with a clamp.
O Fasten the ECU lead with the clamp installed to the
plate of front side hole. Align the positioning tape
and the clamp. Install the clamp to the out side of
plate.
CABLE ROUTING SPEC
P Route the fuel drain hoses (2 hoses), air filter case
drain hose and radiator reservoir tank drain hose
through the guide located behind the swingarm
head pipe. Do not make hoses to cross in the area
between C and D.
Q Pass the radiator reservoir tank drain hose through
right side of the battery negative lead.
R Pass the fuel drain hose and air filter case drain
hose behind the battery negative lead.

–8–
 CABLE ROUTING SPEC
1 Hose 2 A Position of the rear brake light switch lead and start-
2 Hose er relay lead make possible with whichever.
3 Ignition coil assembly B Route the clutch cable through the guide of stay 2.
4 Stay 2 C Direct the rear brake light switch lead to the front.
5 Radiator D Pass the fuel hose between the fuel drain hoses.
6 Clutch cable
7 Rear brake light switch lead
8 Starter relay lead
9 Coolant reservoir tank drain hose
10 Rear brake light switch
11 Fuel tank return hose
12 Fuel hose
13 Fuel tank drain hose

–9–
 CABLE ROUTING SPEC
1 Throttle cable 14 Battery
2 Handlebar switch lead (right) 15 Rectifier/ regulator
3 Stay 16 Starter motor lead
4 Thermo wax hose 17 Battery positive lead
5 Intake vacuum hose 18 Lean angle cut-off switch
6 Sub-wire harness (air filter case) 19 Atmospheric pressure sensor
7 Rear brake light switch lead 20 Fuse (main)
8 Coolant reservoir tank hose 21 Starter relay
9 Oil level switch lead 22 Rear turn signal light lead (right)
10 Fuel injection system relay 23 Rear turn signal light (right)
11 Coolant reservoir tank 24 Tail/ brake light lead
12 Turn signal relay 25 Tail/ brake light
13 Battery band 26 Rear turn signal light lead (left)

–10–
 CABLE ROUTING SPEC
27 Rear turn signal light (left) 39 Bracket 1
28 Immobilizer coupler 40 Hose 1
29 Seat lock cable 41 Air induction system lead
30 Fuse box 42 Coolant temperature sensor lead
31 Battery negative lead 43 Cover
32 Radiator fan motor relay 44 Cover 2
33 Starting circuit cut-off relay 45 main switch lead and immobilizer lead
34 Fuel pump lead 2 46 Handlebar switch lead (left)
35 Fuel pump lead 1 47 Frame
36 Sub-wire harness (throttle body) 48 Wire harness
37 Cylinder identification sensor lead 49 Clamp
38 Radiator fan motor lead

–11–

A Put the cover on the coupler for the immobilizer lead
and wire harness.
B Install the projection part of the coupler pointing to
the connector housing 2.
C Align the projection part of the connector housing 2
with the hole of the locking bracket.
D Attach the boot over the immobilizer coupler.
E Insert the ignition coil lead as shown in the illustra-
tion (left, right).
F To the air induction system.
G For the throttle cable, route the return side cable by
the upper side, and the pull side cable by the lower
side.
H Fasten the coolant reservoir hose, sub wire harness
(air filter case) and intake vacuum hose to the inner
side of the frame with the clamp. Install the clamp
with its opening pointed to the upper side.
–12–
CABLE ROUTING SPEC
I Fasten the sub wire harness (air filter case) to the
inner side of the frame with the wrapping clamp of
the wire harness.
J To the fuel pump.
K Route the starter motor lead under the rear frame
attaching boss section.
L Route the starter motor lead by the right side of the
battery and coolant reservoir tank.
M Route the battery positive lead under the battery
band.
N Pass the rear turn signal light lead (right) through
the right hole of the fender.
O Pass the rear turn signal light leads (right and left)
through the clamp installed to the rear fender. Ad-
just the length of the rear turn signal light lead (left)
by folding and then bundle it.

P Pass the rear turn signal light lead (left) through the
left hole of the fender.
Q Pass the rear turn signal light leads (right and left)
between the ribs of the rear fender.
R Pass the seat locking cable through the hole section
of the seat bracket of the rear frame. Either direction
of the seat locking cable can be accepted.
S Set the immobilizer coupler between the ribs of the
rear fender.
T Route the battery negative lead above the seat
locking cable.
U Route the battery positive lead together with the
starter relay lead as shown in the illustration.
V Route the battery negative lead above the battery.
W Fasten the wire harness to the inner side of the
frame with the harness wrapping clamp.
–13–
CABLE ROUTING SPEC
X Route the wire harness, cylinder identification sen-
sor and radiator fan motor leads under the bracket
1.
Y Route the cylinder identification sensor and radiator
fan motor leads above the radiator hose.
Z To the radiator.
AA Bundle the coolant temperature sensor lead and
air induction system lead with the clamp. Cut the
clamp tip leaving 3 to 8 mm (0.12 to 0.31 in).
BB Bundle the main switch lead, immobilizer lead
and handle bar switch leads (right and left) with
the clamp. Point the tip of the clamp to the front
side and set it between cover and wire harness.
Place the clamp at the right side of the vehicle
from the coupler as shown in the illustration.
CC Fasten the wire harness to both holes of the cover
2 with the harness wrapping clamps.
 CABLE ROUTING SPEC
DD Fasten the cylinder identification sensor and ra-
diator fan motor leads to the frame with the clamp
as shown in the illustration. Point the tip of the
clamp to the downside.
EE Pass the wire harness through the small diameter
side of the clamp and the coolant reservoir tank
drain hose through the large diameter side and
then clamp therm.
FF Clamp the coolant reservoir tank hose and ther-
mo wax hose. Locate of the thermo wax hose un-
der the coolant reservoir tank hose. Opening part
of clamp is downward.

–14–
 FRONT AND REAR BRAKES CHAS
EAS00577

CHASSIS
FRONT AND REAR BRAKES
FRONT BRAKE PADS

6 Nm (0.6 mSkg, 4.3 ftSlb)

40 Nm (4.0 mSkg, 29 ftSlb)

Order Job/Part Q’ty Remarks

Removing the front brake pads Remove the parts in the order listed.
1 Brake caliper bolt 2
2 Brake pad clip 2
3 Brake pad pin 1
4 Brake pad spring 1
5 Brake pad 2
6 Bleed screw 1
For installation, reverse the removal
procedure.

–15–
 FRONT AND REAR BRAKES CHAS
EAS00584

FRONT BRAKE MASTER CYLINDER

10 Nm (1.0 mSkg, 7.2 ftSlb)

30 Nm (3.0 mSkg, 22 ftSlb)

Order Job/Part Q’ty Remarks

Removing the front brake master Remove the parts in the order listed.
cylinder
Brake fluid Drain.
1 Brake lever 1
2 Front brake light switch lead coupler 1 Disconnect.
3 Front brake switch 1
4 Union bolt 1
5 Copper washer 2
6 Master cylinder bracket 1
7 Master cylinder assembly 1
For installation, reverse the removal
procedure.

–16–
 FRONT AND REAR BRAKES CHAS
EAS00585

Order Job/Part Q’ty Remarks

Disassembling the front brake Disassembly the parts in the order listed.
master cylinder
1 Dust boot 1
2 Circlip 1
3 Master cylinder kit 1
4 Spring 1
5 Master cylinder body 1
6 Push rod 1
For assembly, reverse the disassembly
procedure.

–17–
 FRONT AND REAR BRAKES CHAS
EAS00615

FRONT BRAKE CALIPERS

6 Nm (0.6 mSkg, 4.3 ftSlb)

Order Job/Part Q’ty Remarks

Disassembling the front brake Disassemble the parts in the order listed.
calipers The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston seal kit 4
7 Bleed screw 1
For assembly, reverse the disassembly
procedure.

–18–
 CHECKING THE SWITCHES ELEC
EAS00731

ELECTRICAL
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear ! Repair or replace.
Improperly connected ! Properly connect.
Incorrect continuity reading ! Replace the switch.

1 Main switch 7 Clutch switch 13 Fuses

2 Horn switch
3 Pass switch
4 Dimmer switch
5 Hazard switch
6 Turn signal switch
8 Engine stop switch 14 Sidestand switch
9 Start switch
10 Front brake light switch
11 Neutral switch
12 Rear brake light switch

–19–
 IMMOBILIZER SYSTEM ELEC
IMMOBILIZER SYSTEM
SYSTEM DIAGRAM

1 MAIN SWITCH AND IMMOBILIZER UNIT

2 IMMOBILIZER SYSTEM INDICATOR LIGHT
3 ECU

Br . . . . . Brown
Br/ L . . . Brown/ Blue
G/L . . . Green / Blue
R...... Red
R/ G . . . Red/ Green
R/ W . . . Red/ White
Y/ L . . . . Yellow/ Blue

–20–
 IMMOBILIZER SYSTEM ELEC

CIRCUIT DIAGRAM

4 Fuse (main)
8 Battery
9 Main switch
11 Immobilizer unit
12 Fuse (backup)
24 ECU
37 Multi-function meter
39 Immobilizer system
indicator light
60 Fuse (ignition)
67 Fuse (signal)

–21–
 IMMOBILIZER SYSTEM ELEC
GENERAL INFORMATION
S When the main switch is turned “ON” with the registered key, the immobilizer system indicator light
comes on for about 0.5 second and then goes off.
S To check the immobilizer system, follow the steps in the troubleshooting chart.
S To use the immobilizer key, keep it away from other keys. Otherwise, the key code signal may not work
or the correct action may be disturbed.
S The key contains the electronic component (transponder). Do not drop or hit it with a solid metal. Do
not leave it on the dashboard of vehicle where the temperature may rise.
S Do not put it in the water. (when washing clothes for example)
S Do not place it near a magnet or a loud speaker.
S If all keys are missing, the engine control unit (ECU) is required to replace together with the keys and
the immobilizer unit.
S Immobilizer unit cannot be operated with the copy key until the transponder code of the code re-regis-
tering key is registered to the immobilizer unit.
S Total three key codes are registered to the immobilizer unit, which are one code re-registering key
code and two standard key codes.
S Among them, two of standard key codes can be registered to prepare for the case when the key is lost.
To register, the code re-registering key is needed.

1. Code re-registering key (red bow)

2. Standard key (black bow)

–22–
 IMMOBILIZER SYSTEM ELEC
KEY ID REGISTRATION METHOD
Initially one code re-registering key and two standard keys have been registered with the immobilizer
system.
In the course of use, you may encounter the following case where re-registration of code re-register-
ing/standard key is required.

Code re-registering key registration:

When the immobilizer unit or ECU, failed and the unit was replaced, the unit cannot be used until the
key ID is registered because it is not registered to the unit.
a. As usual steps, when the main switch is turned “ON”, the immobilizer system indicator light goes on
for about one second.
b. If the immobilizer system indicator light goes off, it shows that the code re-registering key registra-
tion is finished.
c. Check that the engine can be started.
d. Consequently, carry out the standard key registration, according the section below.

Standard key registration:

When you lost a standard key and need a new one. Or when the code re-registering key is re-registered
after the immobilizer unit or the ECU, are replaced.
a. Check that the immobilizer system indicator light shows the standby mode.
To initiate the standby mode, turn “OFF” the main switch and then it will be the standby mode when it
passes 30 seconds. When 24 hours passed, the standby mode ends and the immobilizer system
indicator light stops flashing.

b. After the main switch is turned “ON” with the code re-registering key, within 5 seconds, turn “OFF”
the main switch and then turn “ON” the main switch with the standard key (the first new key) that you
want to register.
c. It becomes the key registration mode and two standard key IDs that have been stored in the memory
are erased and the first new standard key ID will be registered. At this time, the indicator light quickly
blinks (“OFF” for 0.5 sec. and “ON” for 0.5 sec.).
d. In the condition as mentioned above (while the immobilizer system indicator light continues quick
flashing), after the main switch is turned “ON” with the first new standard key, turn “OFF” the main
switch within 5 seconds, and then turn “ON” the main switch with the standard key that you want to
register (which is the second new key or the standard key remained in hand).
NOTE:
Fast flashing goes off when it elapses 5 seconds and the registration mode is finished. In this case, the
second standard key cannot be registered and only the first standard key is registered.

–23–
 IMMOBILIZER SYSTEM ELEC
e. When the registration is finished, the immobilizer system indicator light goes off.
f. Check that the engine can be started with the registered two standard keys.

Code re-registering First unregistered

When one key
standard key
standard key
is registered.
Flashing ends when it elapses 5 seconds and the
registration for the seconds standard key is impossible.

When two Code re-registering

key
First unregistered Second unregistered
standard key
standard key
standard keys
are registered.

Flashing ends when the registration of the seconds

unregistered standard key is complete.

Important note:
If you lost a standard key, immediately re-register your code re-registering key and the remaining stan-
dard key (if any). This will delete the stored registration data, protecting the motorcycle against being
started with the lost key.

–24–
 IMMOBILIZER SYSTEM ELEC
SELF-DIAGNOSIS ERROR CODE INDICATION
When the system failure occurred, the error code number is indicated in the LCD display of meter and
the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the
error code.
Error code Detection Symptoms Trouble Measures
51 Immobilizer Cannot transmit code be- 1) Objects that may keep off radio 1) Keep clear of magnets, metals
tween the key and immobiliz- waves exist around the keys and and other keys from the sur-
er unit. antennas. roundings of keys and antennas.
2) Immobilizer unit failure 2) Replace the immobilizer unit.
3) Key failure 3) Replace the key.
52 Immobilizer Codes do not match between 1) Disturbed by other transponder. 1) Place the immobilizer unit away
the key and immobilizer unit. Failed to verify continually for ten more than 50 mm from the trans-
times. ponder of other vehicle.
2) Unregistered standard key was 2) Register the standard key.
used.
53 Immobilizer Cannot transmit code be- Noise interference or disconnected 1) Check the wire harness and con-
tween the ECU and immobi- lead / cable. nector.
lizer unit. 1) Obstruction due to radio wave 2) Replace the immobilizer unit.
noise. 3) Replace the ECU.
2) Error by disconnection of the
communication harness.
3) Immobilizer unit failure.
4) ECU failure.
54 Immobilizer Codes do not match between Noise interference or disconnected 1) Register the code re-registering
ECU and immobilizer unit. lead / cable. key ID.
1) Obstruction due to radio wave 2) Check the wire harness and con-
noise. nector.
2) Error by disconnection of the 3) Replace the immobilizer unit.
communication harness. 4) Replace the ECU.
3) Immobilizer unit failure
4) ECU failure
(When the used parts from other
vehicles are used, the code re-
registering key ID is not regis-
tered to the ECU.)
55 Immobilizer Key code registration error. Same standard key was attempted Prepare the new standard key and
to continuously two times register. register it.
56 ECU Undefinition code is re- Noise interference or disconnected 1) Check the wire harness and con-
ceived. lead / cable. nector.
1) Obstruction due to radio wave 2) Replace the immobilizer unit.
noise. 3) Replace the ECU.
2) Error by disconnection of the
communication harness.
3) Immobilizer unit failure.
4) ECU failure.

Immobilizer system indicator light code indication

Digit of 10 : Cycles of 1 sec. “ON” and 1.5 sec. “OFF”.
Digit of 1 : Cycles of 0.5 sec. “ON” and 0.5 sec. “OFF”.

<Example> 52

Light ON

Light OFF

–25–
 IMMOBILIZER SYSTEM ELEC
EAS00794 EAS00739

TROUBLESHOOTING 2. Battery
S When the main switch is turn “ON”, the S Check the condition of the battery.
immobilizer system indicator light does Refer to “CHECKING AND CHARGING
not come on or flashing. THE BATTERY” in chapter 3. (Manual No.:
5PS1-AE1)
Check:
1. main, ignition, and backup fuses Minimum open-circuit voltage
2. battery 12.8 V or more at 20_C (68_F)
3. main switch S Is the battery OK?
4. wiring connections
(of the entire immobilizer system) YES NO
NOTE:
S Before troubleshooting, remove the following S Clean the battery
part(s): terminals.
1. seat S Recharge or re-
2. fuel tank place the battery.
3. side cowlings
S Troubleshoot with the following special tool(s).
EAS00749

3. Main switch
Pocket tester S Check the main switch for continuity.
90890-03112, YU-3112 Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
EAS00738

1. Main, ignition and backup fuses YES NO

S Check the main, ignition and backup fuses
for continuity. Replace the main
Refer to “CHECKING THE FUSES” in chap- switch.
ter 3. (Manual No.: 5PS1 -AE1)
S Are the main, ignition and backup fuses OK?
EAS00787

YES NO 4. Wiring
S Check the entire immobilizer system’s wir-
Replace the fuse(s). ing.
Refer to “CIRCUIT DIAGRAM”.
S Is the immobilizer system’s wiring properly
connected and without defects?

YES NO

Check the condition Properly connect or

of each of the immo- repair the immobiliz-
bilizer system’s cir- er system’s wiring.
cuits.
Refer to “CHECKING
THE IMMOBILIZER
SYSTEM”.

–26–
 IMMOBILIZER SYSTEM ELEC
EAS00788

CHECKING THE IMMOBILIZER SYSTEM 3. Wiring

1. The immobilizer system indicator light S Disconnect the meter coupler and immobi-
does not come on. lizer unit coupler.
S Check the immobilizer system indicator light
1. Immobilizer system indicator light (LEDs)
lead (green/blue) continuity.
S Check the immobilizer system indicator light (meter coupler – immobilizer unit coupler).
continuity. S Is the immobilizer system indicator light lead
Refer to “CHECKING THE LEDs”. (Manual OK?
No.: 5PS1-AE1)
S Are the immobilizer system indicator light YES NO
(LEDs) OK?
Replace the immobi- The wiring circuit
YES NO
lizer unit. from the meter to im-
mobilizer unit is
Replace the meter faulty and must be
assembly. repaired.

2. The LCD display does not indicated.

1. Voltage
2. Voltage
S Connect the pocket tester (DC 20 V) to the
S Connect the pocket tester (DC 20 V) to the
meter coupler as shown.
immobilizer unit coupler as shown.

LCD display
Positive tester probe !
Positive tester probe !
red/white 1 or red/green 2
brown 1 or red/green 2
Negative tester probe ! black 3
Negative tester probe ! black/white 3
S Turn the main switch to “ON”.
S Turn the main switch to “ON”.
S Measure the voltage (DC 12 V) on the immo-
S Measure the voltage (DC 12 V) meter cou-
bilizer unit coupler (wire harness side).
pler (wire harness side).
S Is the voltage within specification?
S Is the voltage within specification?
YES NO
YES NO

The wiring circuit

Replace the meter. The wiring circuit
from the main switch
from the main switch
to the immobilizer
to the meter coupler
unit coupler is faulty
is faulty and must be
and must be re-
repaired.
paired.

–27–
 IMMOBILIZER SYSTEM ELEC
2. When the main switch is turned “ON”, the immobilizer system indicator light is flashing.
S Check if the metallic obstacle or the transponder of other vehicle exists near the immobilizer unit. If
it exists, eliminate it and recheck the condition.

Turn “ON” the main switch with another

standard key and check the immobiliz- Correct
First standard key (Transponder) de-
er system indicator light. The immobi- fective
lizer system indicator light goes on for
about one second and then goes off.

Failure

Turn “ON” the main switch with code Correct Two standard Resister
re-registering key and check the immo- key (Transpond- again
bilizer system indicator light. er) defective
Failure
Failure

Replace
the key

Check the self-diagnosis code indica- Indicated Read the error code and inspect the
tion. corresponding part.
Refer to “SELF-DIAGNOSIS ERROR
No indication CODE INDICATION”.

Immobilizer Unit failure or ECU failure

Check the signal lead (yellow / blue) Failure Yellow/ blue lead is disconnected or
between the immobilizer unit and ECU short-circuited. Repair or replace the
connector. circuit.

Correct

Replace the immobilizer unit.

–28–
 IMMOBILIZER SYSTEM ELEC
REPLACEMENT PARTS ON TROUBLES
Replacement parts
Immobilizer *1Main *2Accessory
Transponder Key ECU
Unit Switch Lock And Key
When standard key is missing
and the replace standard key f
is required
All keys have been lost (includ-
f f f f f
ing code re-registering key)
ECU is defective f
When the immobilizer
f
unit is defective
When the main switch is
f f f f f
defective
When the accessory lock is
f
defective

*1 There is no parts setting as a single unit. It will be the replacement in a set with the IMMOBILIZER UNIT.
*2 Accessory lock means the seat lock, fuel filler cap or the helmet holder.
NOTE:
S To replace the single unit of ECU, first turn “ON” the main switch with the code re-registering key. This
operation allows the code re-registering key ID to be registered to the new ECU. Register the stan-
dard key subsequently.
S To replace the single unit of immobilizer unit, first turn “ON” the main switch with the code re-register-
ing key. This operation allows the code re-registering key ID to be registered to the new immobilizer
unit. Register the standard key subsequently.

–29–
WIRING DIAGRAM
1 Crankshaft position sensor 62 Right handlebar switch
2 A.C. magneto 63 Front brake light switch
3 Rectifier/ regulator 64 Engine stop switch
4 Fuse (main) 65 Start switch
5 Fuse (fuel injection system) 66 Fuse (hazard)
6 Starter relay 67 Fuse (signal)
7 Starter motor 68 Rear brake light switch
8 Battery 69 Tail/ brake light switch
9 Main switch 70 Auxiliary light
10 Alarm 71 Fuse (radiator fan motor)
11 Immobilizer unit 72 Radiator fan motor relay
12 Fuse (backup) 73 Radiator fan motor
13 Starting circuit cut-off relay
14 Sidestand switch
15 Neutral switch
16 Cylinder identification sensor COLOR CODE
17 Throttle position sensor
B ....... Black
18 Intake air pressure sensor
Br . . . . . . Brown
19 Atmospheric pressure sensor
Ch . . . . . Chocolate
20 Intake air temperature sensor
Dg . . . . . Dark green
21 Coolant temperature sensor
G ...... Green
22 Lean angle cut-off switch
Gy . . . . . Gray
23 O2 sensor
L ....... Blue
24 ECU
Lg . . . . . . Light green
25 Injector #1
O ...... Orange
26 Injector #2
P ....... Pink
27 Air cut-off valve
R....... Red
28 Intake solenoid
Sb . . . . . . Sky blue
29 Ignition coil #1
W ...... White
30 Ignition coil #2
Y ....... Yellow
31 Spark plug
B/ L . . . . . Black/ Blue
32 Fuel pump
B/ W . . . . Black/ White
33 Speed sensor
B/ Y . . . . Black/ Yellow
34 Meter assembly
Br/ B . . . . Brown/ Black
35 Oil level warning light
Br/ G . . . Brown/ Green
36 Neutral indicator light
Br/ L . . . . Brown/ Blue
37 Multi-function meter
Br/ R . . . . Brown/ Red
38 Engine trouble warning light
Br/ W . . . Brown/ White
39 Immobilizer system indicator light
G/B . . . . Green / Black
40 High beam indicator light
G/L . . . . Green / Blue
41 Left turn signal light
G/R . . . . Green / Red
42 Right turn signal indicator light
G/W . . . . Green / White
43 Meter light
G/Y . . . . Green / Yellow
44 Oil level switch
Gy/ G . . . Gray / Green
45 Left handlebar switch
Gy/ R . . . Gray / Red
46 Horn switch
L/B . . . . . Blue/ Black
47 Pass switch
L/G . . . . Blue/ Green
48 Dimmer switch
L/R . . . . Blue/ Red
49 Hazard switch
L/W . . . . Blue/ White
50 Turn signal switch
L/Y . . . . . Blue/ Yellow
51 Clutch switch
P/ W . . . . Pink/ White
52 Turn signal relay
R/ B . . . . Red/ Black
53 Horn
R/ G . . . . Red/ Green
54 Rear turn signal light (left)
R/ L . . . . Red/ Blue
55 Rear turn signal light (right)
R/ W . . . . Red/ White
56 Front turn signal light (left)
R/ Y . . . . Red/ Yellow
57 Front turn signal light (right)
W/ B . . . . White/ Black
58 Headlight
W/ Y . . . . White/ Yellow
59 Headlight relay
Y/ B . . . . Yellow/ Black
60 Fuse (ignition)
Y/ G . . . . Yellow/ Green
61 Fuse (head)
Y/ L . . . . . Yellow/ Blue
TDM900 (S) 2004 WIRING DIAGRAM